Method and apparatus of forming a bagpipe chanter

ABSTRACT

A method of forming a chanter ( 100 ) suitable for use with a bagpipe is provided. The method includes applying a first material ( 132 ) about an outer surface ( 130 ) of a mold ( 102 ) and attaching a first fitting ( 134 ) to the first material. The method further includes attaching a second fitting ( 152 ) to the first material at a selected separation distance from the first fitting to form a unitary body ( 166 ) and removing of the unitary body from the mold. A mold ( 102 ) used in forming a chanter ( 100 ) of a bagpipe is also provided. The mold includes a first tapered portion ( 104 ) having an outer surface and a second tapered portion ( 106 ) having an outer surface. At least a portion of the outer surfaces of the first and second tapered portions collectively form at least a portion of a shape of an inner longitudinally oriented air passageway of a chanter.

FIELD OF THE INVENTION

[0001] The present invention relates generally to methods of forming chanters and, more particularly, to methods of forming chanters using composite materials.

BACKGROUND OF THE INVENTION

[0002] Chanters of bagpipes are typically formed from wood, with the exception of practice chanters, which are sometimes formed from plastics. In formation, a piece of stock material, either of wood or plastic, is machined upon a lathe to form the outer surface of the chanter. The stock material is then bored along a longitudinal axis of the stock material to create an inner air passageway. The chanter is then drilled perpendicular to the longitudinal axis to form finger note holes to allow the user to perform note changes during use.

[0003] Although previously developed methods for forming chanters are effective, they are not without their problems. For instance, the methods of lathe machining and boring produces chanters that are slightly different between successively manufactured chanters due to tolerances in the machining process. Thus, each chanter formed is unique. These slight differences between chanters cause each chanter to have a unique sound, which when several bagpipes are played simultaneously, can cause discontinuities in the sounds produced, which may be displeasing to the ear. Further, for the wood formed chanters, the preferred wood is African black wood. Although African black wood may produce a pleasant sound in a chanter, it is limited in supply, thus costly, and is prone to warping and cracking, which distorts the sound of the chanter and causes the longevity of the chanter to be significantly reduced.

SUMMARY OF THE INVENTION

[0004] In accordance with one embodiment of the present invention, a method of forming a chanter suitable for use with a bagpipe is provided. The method includes applying a first material about an outer surface of a mold and attaching a first fitting to the first material. The method further includes attaching a second fitting to the first material at a selected separation distance from the first fitting to form a unitary body and removing of the unitary body from the mold.

[0005] In accordance with another embodiment of the present invention, a method of forming a chanter suitable for use with a bagpipe is provided. The method includes applying a first material upon a split mold having a first portion and a second portion and forming a first fitting upon the first material. The method further includes forming a second fitting upon the first material at a selected separation distance from the first fitting and curing the first material, thereby forming a unitary body including the first material and the first and second fittings. The method still further includes removal of the first portion from the second portion of the split mold and removal of the unitary body from the second portion of the mold.

[0006] In accordance with still another embodiment of the present invention, a mold used in forming a chanter of a bagpipe is provided. The mold includes a first tapered portion having an outer surface. The mold also includes a second tapered portion having an outer surface, the second tapered portion operable to removably couple to the first tapered portion such that at least a portion of the outer surfaces of the first and second tapered sections collectively form at least a portion of a shape of an inner longitudinally oriented air passageway of a chanter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The foregoing aspects and many of the attendant advantages of this invention will become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0008]FIG. 1 is an exploded view of a partially completed chanter shown in relation to a mold and a split spacer used in the formation of a chanter, the mold, split spacer and partially completed chanter all formed in accordance with one embodiment of the present invention;

[0009]FIG. 2 is a cross-sectional view of the mold shown in FIG. 1, wherein the cross-sectional cut is taken substantially through section 2-2 of FIG. 1, wherein the mold is shown in assembled form;

[0010]FIG. 3 is a cross-sectional view of the mold shown in FIG. 2, wherein a first material formed in accordance with one embodiment of the present invention has been applied to the mold, the first material also shown in cross-section;

[0011]FIG. 4 is a cross-sectional view of the mold and first material shown in FIG. 3, wherein the first material has been impregnated with a second material formed in accordance with one embodiment of the present invention;

[0012]FIG. 5 is a cross-sectional view of the mold and first and second materials shown in FIG. 4, wherein a first fitting is shown engaged by a base formed in accordance with one embodiment of the present invention and by the first and second materials, the first fitting also shown in cross-section;

[0013]FIG. 6 is a cross-sectional view of the mold, first and second materials, and first fitting shown in FIG. 5, wherein a second fitting formed in accordance with one embodiment of the present invention is shown spaced a selected separation distance from the first fitting by the split spacer, the second fitting also shown in cross-section; and

[0014]FIG. 7 is a perspective view of a finished chanter formed in accordance with one embodiment of the present invention, wherein a portion of an outer second coating is removed to better show an underlying first coating.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0015] FIGS. 1-6 illustrate one embodiment of a method of forming a chanter 100 in accordance with one embodiment of the present invention, the completed chanter 100 illustrated in FIG. 7. FIGS. 1-6 also illustrate a mold 102 used in the formation of the chanter 100 shown in FIG. 7. Referring to FIGS. 1 and 2, the mold 102 in the illustrated embodiment includes a tip 104, a main body 106, and a base 108.

[0016] The tip 104 is suitably a truncated cone, tapering along a longitudinal length of the tip 104 from a first diameter at a first distal end 112 to a second smaller diameter at a second distal end 114. The tip 104 includes an attachment shaft 116 configured to cooperatively mate within a receiving cavity 118 in the main body 106. The attachment shaft 116 removably attaches the tip 104 to the main body 106.

[0017] The main body 106 is generally shaped as an elongated truncated cone, tapering along a longitudinal length of the main body 106 from a first diameter at a first distal end 120 to a second smaller diameter at a second distal end 122. The receiving cavity 118 for cooperatively mating with the attachment shaft 116 of the tip 104 is disposed in the second distal end 122 of the main body 106, thereby allowing the removable coupling of the tip 104 to the main body 106. Although specific structures for mating the tip 104 to the body 106 is depicted in the illustrated embodiment, it should be apparent to those skilled in the art that alternate mating methods are suitable for use and within the spirit and scope of the present invention.

[0018] The base 108 is suitably circular in shape and includes a centrally located bore extending therethrough. The bore has a diameter 124 sized to form an interference fit with the main body 106. Although in the illustrated embodiment the base 108 is coupled to the main body 106 through an interference fit, it should be apparent to those skilled in the art that other methods of attachment are suitable for use and within the scope of the present invention, such as integrally forming the base 108 with the main body 106, supporting the base 108 with a shoulder or lip in the main body 106, supporting the base 108 with structure located externally of the mold 102, etc. It should also be apparent that the base may be eliminated all together and, therefore, such an embodiment is also within the scope of the present application.

[0019] The inner diameter 124 of the base 108 may be tapered to correspond to the taper of the main body 106. As should be apparent to those skilled in the art, alternate bases may be formed having varying inner diameters 124 such that the location along the length of the main body 106 at which the base 108 forms an interference fit may be selected by choosing a base 108 having an inner diameter 124 corresponding to the outer diameter of the main body 106 at the location of desired interference fit. Thus, the position of the base 108 between the first and second distal ends 120 and 122 of the main body 106 may be determined by selecting a base 108 having an appropriately sized inner diameter 124.

[0020] To assemble the mold 102, a base 108 having an appropriately sized inner diameter 124 selected by the user is placed upon the main body 106 until the inner diameter 124 forms an interference fit with the main body 106. The attachment shaft 116 of the tip 104 is inserted within the receiving cavity 118 of the main body 106, removably coupling the tip 104 to the main body 106 to form a waist 126 at their interface. The waist 126 includes an outer diameter. The outer diameter represents the smallest outer diameter of the mold 102 found between the base 108 and a second fitting 152 (see FIG. 6).

[0021] A mold release agent 128 is applied to an outer surface 130 of the mold 102. One suitable mold release agent 128 is wax, another being a Polyvinyl Alcohol (PVA) based mold release agent. It should be apparent to those skilled in the art that other mold release agents 128, are also within the scope of the present invention.

[0022] Referring to FIG. 3, a first material 132 is applied to the outer surface 130 of the mold 102 and extends between the base 108 and a selected location above the waist 126. In the illustrated embodiment, the first material 132 abuts the base 108, however, it should be apparent to those skilled in the art that the first material 132 may also alternatively flare out onto the base 108. In one embodiment, the first material 132 includes reinforcing fibers, a few suitable examples being carbon, glass, or aramid reinforcing fibers. In another embodiment, the first material 132 includes individual strands 131 woven or interlaced into a tubular weave and slipped onto the mold 102, such that the mold 102 passes through the center of the tubular weave. In still yet another embodiment, the reinforcing fibers of the first material 132 are collected into strands 131 which are interlaced with one another (woven) such that the length of individual strands 131 pass at oblique angles relative to a longitudinal axis of the mold 102 when disposed on the mold 102. Woven as such, the diameter of the tubular weave forming the first material 132 may be selectively adjusted by pulling on the tubular weave along its longitudinal length, thereby causing a corresponding decrease in the diameter of the tubular weave of the first material 132 so as to conform the first material 132 to the shape of the mold 102. In another alternate embodiment, the first material 132 is wound upon the mold 112 by techniques well known in the art.

[0023] Referring to FIG. 4, a second material 133 is placed upon the first material 132. In the illustrated embodiment, the second material 133 is suitably a fluid capable of hardening into a solid. In the illustrated embodiment, the second material 133 impregnates interstices of the first material 132, such as between the interstices of individual reinforcing fibers of the first material 133, to form a composite material. In one embodiment, the second material 133 is a polymer matrix, such as a plastic. In another embodiment, the first material 132 is impregnated with a second material 133 that is a thermoplastic or thermoset resin, such as a polyester, isophthalic polyester, isopolyester, vinyl ester, epoxy, or phenolic resin. Although in the illustrated embodiment, the second material 133 is placed upon the first material 132 after the first material 132 has been laid upon the mold 102, it should be apparent to those skilled in the art that other methods are also within the scope of the present application. As a non-limiting example the first material 132 may be preimpregnated with the second material 133 and then laid upon the mold 102, such that resulting configuration is a combination of the first and second materials 132 and 133.

[0024] Referring to FIG. 5, a first fitting 134, in the form of a disc having an inner diameter 136, is disposed upon the mold 102 such that the mold 102 passes through the inner diameter 136. The first fitting 134 is referred to as a “soul” in the art of chanter manufacturing and is adapted to be coupled to the bag portion of a bagpipe. The first fitting 134 is positioned to engage the base 108 such that the first fitting 134 is supported thereupon. The inner diameter 136 of the first fitting 134 engages the first and second materials 132 and 133. A third material 138 is placed at the interface of the upper surface of the first fitting 134, the inner diameter 136 of the first fitting 134 and the first and second materials 132 and 133. The third material 138 is suitably a pliable material, such as a paste or curable liquid. Some examples of suitable materials are polyester or epoxy putties. The third material 138 forms a contoured transition, such as a bevel or chamfer, between the first fitting 134 and the first and second materials 132 and 133. The first fitting 134 is suitably formed from fiberglass. Although a first fitting formed from fiberglass has been described, the first fitting may also be formed from other materials, such as any rigid or semi-rigid material, same suitable examples being plastic, metal, wood, etc.

[0025] Referring to FIG. 6, a spacer 142 is placed upon the first fitting 134. The spacer 142 includes an elongated cylindrical structure encircling the mold 102. The spacer 142 may include a split along its longitudinal length such the spacer 142 is bifurcated into first and second halves 144 and 146. As best seen in FIG. 1, the first and second halves 144 and 146 may be placed around the mold 102 and secured to one another by any method known in the art, such as by strapping materials, clamps, etc. (not shown for clarity.)

[0026] Returning to FIG. 6, the spacer 142 is formed by securing a small diameter split pipe 148 within a larger diameter split pipe 150, such that the outer diameter of the small diameter split pipe 148 engages the inner diameter of the large diameter split pipe 150. As discussed in further detail below, the length of the spacer 142 is chosen to allow adjustment of a separation distance extending between the first and second fittings 134 and 152. Although a specific construct of a spacer 142 has been described, it should be apparent to those skilled in the art that any number of constructs of spacers 142 are suitable to provide a separation distance between the first and second fitting 134 and 152 and, therefore are also within the scope of the present invention. For instance, spacers constructed from posts, preferably three or more which extend between the first and second fittings 134 and 152, or horse shoe or forked shaped support members which engage and support the first and second fittings 134 and 152 are within the scope of the present invention.

[0027] The second fitting 152 is commonly known in the art of chanter manufacturing as a “reed seat,” and is adapted to receive a reed therein. The second fitting 152 includes a cylindrical portion 154 having an outer surface 156. A disc 158 is placed upon the outer surface 156 of the cylindrical portion 154 to form a base 160. The cylindrical portion 154 and disc 158 are coupled to each other by an interference fit. Although an interference fit has been described, it should be apparent that the cylindrical portion 154 and disc 158 they may be coupled together in any number of ways, including integrally forming the disc 158 with the base 160.

[0028] The second fitting 152 is disposed upon the mold 102 such that the mold 102 and first and second materials 132 and 133 pass through the second fitting 152. The second fitting 152 is positioned to engage the spacer 142 such that the second fitting 152 is supported thereupon at a selected separation distance from the first fitting 134. A fourth material 162, substantially similar to the third material 138, is placed at an interface between the lower surface 164 of the base 160 and the first and second materials 132 and 133. The fourth material 162 forms a contoured transition, such as a bevel or chamfer, between the base 160 and the first and second materials 132 and 133. The second fitting 152 is suitably formed from fiberglass or any suitable rigid or semi-rigid material, such as plastic, wood, metal, etc.

[0029] Referring to FIGS. 1, 6 and 7, the first and second materials 132 and 133 are cured by any suitable means known in the art, such as oven curing or leaving the first and second materials 132 and 133 to cure at room temperature. Once sufficiently cured, a unitary body 166 comprising the first fitting 134, the second fitting 152, the first, second, third and fourth materials 132, 133, 138, and 162 is formed. The spacer 142 may be removed by disengaging the first half 144 of the spacer 142 from the second half 144 of the spacer 142. The tip 104 may be disengaged from the main body 106 of the mold 102 by applying an upward separation force to the tip 104. An upward separation force may be applied to the base 108 to disengage the unitary body 166 from the main body 106 of the mold 102. Finger note holes 168 are formed in the unitary body 166 by techniques well known in the art. The finger note holes 168 are oriented perpendicular to the longitudinal axis of the unitary body 166 in locations well known in the art.

[0030] A first coating 170 may be applied to the exterior of the unitary body 166. In the illustrated embodiment, the first coating 170 is a gel coat, such as a quick-setting resin. However, it should be apparent that any number of coatings 170 known to those skilled in the art and able to provide at least an improved surface appearance and texture are also suitable for use with certain embodiments of the present invention. One such suitable coating 170 is a high-build, chemical-resistant, thixotropic polyester coating.

[0031] The exterior surface of the unitary body 166 is then machined, such as by a lathe, to provide a selected exterior surface shape. The exterior surface of the unitary body 166 may then be painted with any suitable paint, such as a linear polyurethane epoxy, to form a second coating 172 upon the unitary body 166. The second coating 172 may be textured to provide a textured surface amenable to provide a gripping surface for the hands of the user. In one method practiced in accordance with the present invention, the exterior surface is textured with sand paper to a selected surface roughness.

[0032] While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. 

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
 1. A method of forming a chanter suitable for use with a bagpipe comprising: (a) applying a first material about an outer surface of a mold; (b) attaching a first fitting to the first material; (c) attaching a second fitting to the first material at a selected separation distance from the first fitting to form a unitary body; and (d) removing of the unitary body from the mold.
 2. The method of claim 1, wherein the first material comprises reinforcing fibers.
 3. The method of claim 1, further comprising impregnating the first material with a fluid curable into a solid.
 4. The method of claim 1, further comprising curing the unitary body.
 5. The method of claim 1, further comprising placing a spacer between the first and second fittings to position the first fitting at the selected separation distance from the second fitting.
 6. The method of claim 1, further comprising: (a) placing a first portion of a spacer between the first and second fittings; (b) placing a second portion of the spacer between the first and second fittings; and (c) joining the first and second portions of the spacer to one another.
 7. The method of claim 1, further comprising placing a removable base upon the mold, the removable base adaptable to engage one of the first or second fittings.
 8. The method of claim 7, wherein removing the unitary body from the mold further comprises; (a) splitting the mold into at least a first portion and a second portion; (b) removing the first portion of the mold; and (b) imparting a force upon the base to initiate movement of the unitary body, thereby releasing the unitary body from the second portion of the mold.
 9. The method of claim 1, further comprising forming a coating upon an outer surface of the unitary body.
 10. The method of claim 9, wherein the coating is a gelcoat.
 11. The method of claim 9, further comprising modifying the coating to provide a textured gripping surface to the coating.
 12. The method of claim 1, wherein at least a portion of the outer surface of the mold is shaped to substantially match an inner surface of a chanter.
 13. The method of claim 1, wherein the mold comprises at least two pieces removably coupled to one another.
 14. The method of claim 1, wherein the mold comprises a tip having a length removably coupled to a main body having a length, wherein the tip and main body are tapered along their respective lengths.
 15. The method of claim 14, wherein the top is tapered along its length in a first direction and the main body is tapered along its length in a second direction opposite the first direction.
 16. The method of claim 1, further comprising applying a mold release agent to the mold prior to applying the first material.
 17. The method of claim 1, wherein the first material comprises carbon fibers.
 18. The method of claim 1, wherein the first material is in the form of a tubular weave.
 19. The method of claim 18, wherein the tubular weave is formed from individual strands of the first material, the individual strands interwoven so as to pass at oblique angles to a longitudinal axis of the mold when the tubular weave is disposed upon the mold.
 20. The method of claim 1, further comprising forming holes in the unitary body, wherein the holes are oriented substantially perpendicular to a longitudinal axis of the unitary body.
 21. The method of claim 1, further comprising placing a third material at the interface of the first material and the first or second fitting to provide a contoured surface between the first material and the first or second fitting.
 22. A method of forming a chanter suitable for use with a bagpipe comprising: (a) applying a first material upon a split mold having a first portion and a second portion; (b) forming a first fitting upon the first material; (c) forming a second fitting upon the first material at a selected separation distance from the first fitting; (d) curing the first material, thereby forming a unitary body including the first material and the first and second fittings; (e) removal of the first portion from the second portion of the split mold; and (f) removal of the unitary body from the second portion of the mold.
 23. The method of claim 22, wherein the first material comprises a tubular weave of material, wherein the split mold is placed within the tubular weave of material.
 24. The method of claim 22, further comprising placing a fluid upon the first material, the fluid curable into a solid.
 25. The method of claim 22, wherein the split mold has a longitudinal length and the split mold is split laterally into the first portion and the second portion at an interface.
 26. The method of claim 25, wherein a smallest outer diameter of the mold found between the first and second fittings is located at the location of the interface.
 27. The method of claim 22, wherein the first fitting is disc shaped.
 28. The method of claim 22, wherein the second fitting includes a cylindrical portion and a disc shaped base portion.
 29. The method of claim 22, further comprising machining the unitary body to create an outer surface of the unitary body having a preselected shape.
 30. The method of claim 22, further comprising placing a coating upon the unitary body.
 31. The method of claim 30, wherein the coating is a paint.
 32. The method of claim 30, wherein the coating is a gelcoat.
 33. The method of claim 31, further comprising modifying the paint to provide a textured finish.
 34. The method of claim 22, wherein the unitary body is removed from the split mold by splitting the mold into at least a first portion and a second portion and removing the first and the second portions from the unitary body.
 35. A mold used in forming a chanter of a bagpipe, the mold comprising; (a) a first tapered portion having an outer surface; and (b) a second tapered portion having an outer surface, the second tapered portion operable to removably couple to the first tapered portion such that at least a portion of the outer surfaces of the first and second tapered portions collectively form at least a portion of a shape of an inner longitudinally oriented air passageway of a chanter. 